Theegarten-Pactec in Dresden: SANHA piping systems in use
The Theegarten-Pactec GmbH & Co. KG is a specialist in designing and manufacturing packaging machines for confectionery. The new administration and production building began operations in July of 2015 at the company headquarters in Dresden. SANHA products were used for the majority of the heating and cooling installations.
Changes at the company headquarters
The first of three phases has been completed with the construction of the main office building and the first part of the assembly/manufacturing facility, where state-of-the-art packaging machines for making small-sized confectionery are produced. The medium-sized family-run business Theegarten-Pactec, invested around EUR 30 million in order to solidify their successful position as market leader in packaging technology.
A particular challenge for the client, staff and contractors was to carry out the demolition of the existing buildings, and building of the new construction on the premises, during normal operations. Retaining the existing building, dating from the 1950’s was not possible for as it was no longer compatible with modern useage.
The Vollack Group, a specialist in construction design and management took over the general planning and project supervision for Theegarten-Pactec GmbH & Co. KG.
Based on ongoing operational requirements, future strategy, local conditions and budget specifications, a masterplan was developed. The factory site was expanded by 12,000 m² in the course of the project to 50,000 m².
About the building
The building is divided into two sections according to usage. The first is 5,500 m² of office space built according to the KfW energy efficiency standard, the remaining area consists of 15,500 m² full surface, crane-operated assembly areas and production spaces.
The client also had a stylish canteen built with a terrace, that opens onto the courtyard for the approximately 400 employees in Dresden. The project was funded under the KfW scheme 242 (funding of energy efficiency measures of commercial enterprises). All investment measures that achieve substantial energy savings, including in the areas of building envelopes or plant engineering can attract significant grants.
The building is heated largely by district heating. In addition, the heat pump with a capacity of 357 kW, which was installed on the roof, was also used for heating during the transition period. Because the system uses a under floor heating system, with low flow temperatures, greater efficient use of energy can be achieved. In summer, the heat pump provides the necessary cooling capacity for offices and production via ceiling-mounted convectors and a ventilation system.
Quality installation products
Those responsible for realising the project chose the SANHA®-Therm installation system to meet the high standards. The system consists of press fittings made of carbon steel with a black moulded seal made of EPDM (ethylene propylene rubber) and carbon steel pipes certified according to DIN EN 10305-3. Dimensions between 15–76 mm were used. SANHA®-Therm is particularly suitable for closed heating systems.
Dimensions 15 to 54 mm, from the NiroTherm® system made of stainless steel of type 1.4301 were combined with SANHA-Therm fittings for cooling/cold water. SANHA-Therm was also used in dimensions over 54 mm. The fittings in small diameters and pipes over 54 mm were given a double anti-corrosion coating according to the AGI (AGI Q151-EU Corrosion Protection Under Insulation) standard before they were insulated together with the pipes. This procedure protects the material from corrosion caused by condensation to ensure a permanent, secure connection between the cooling units on the roof and the delivery points. The cooling and cold water pipes were also equipped with special pipe clamps which contribute to providing 100 per cent oxygen-tight insulation.
Combipress for a simple installation
During installation, the contracting company Bauhof West GmbH, based in Dresden relied on close cooperation with SANHA. The company based in Essen supported the installers throughout the entire construction period with their technical expertise and practical experience. The cooperation was complemented by extensive training on the construction site. Mike Oliver Michael, Head of Heating Installation at Bauhof West GmbH, commented, “This kind of positive collaboration has helped us to finish this job on time.”
In total, Bauhof West GmbH installed 3,300 m of pipes and numerous fittings within the specified period of time. Combipress, the combination of the push and stay, and leak path feature, was of great benefit to the installer. The result is pipes and fittings that are efficiently joined together, without immediately sliding apart again. This simplifies installation work significantly especially when working upside down. At the same time, the connection is not airtight until it is pressed professionally. Unpressed joints are detected when following the SANHA testing protocol., available on their web site.
The third element of combipress is tool compatibility. It ensures that fittings and pipes up to 54 mm with press jaws or collars can be pressed with an original contour by SANHA, Mapress or Viega. Original contours by SANHA and Mapress are used up to 108 mm. (Please note, a Copper Only sling is required when using Copper.) Installers can therefore save time and money by using existing tools. Also any risk of confusion of tools at the site is avoided which also further increases the safety and reliability of the joints. “When it comes to working quickly day-to-day on a construction site, combipress is a big help,” affirms Mike Oliver Michael. “The fewer errors there are, the better the result.”
Initial experience
After moving into the new building, the client was completely satisfied with the final result. The new spaces created offer very good installation conditions for complex lines of packaging machines, for achieving smooth project workflows between customers and Theegarten-Pactec. Continuous, properly working heating and cooling systems, is of great importance when it comes to the thermal comfort and therefore the employee’s ability to perform their jobs, yet also key to an effective refrigeration chain for production. This is ultimately ensured through the use of high quality systems from SANHA which have been manufactured to the highest engineering standards.
